Laminated body and method of making same



Oct. 9, 1934. wI HARPER, JR

LAMINATED BODY AND METHOD 0F MAKING SAME Filed March l2, 1930 2Sheets-Sheet INVENToR WILLIAM HARPER JR.

ATTORNEY Oct. 9, 1934. I w. HARPER, A.1R 1,976,257

LAMINATED BODY AND METHOD OF MAKING SAME Filed March l2, 1930 '2Sheets-Sheet 2 lNvENToR WILLIAM HARPER JR.

ATTORNEY Planea oci. e, 1934 UNITED `sTillTI-:s PATENT or-s'Flcl-z mmmvoor nm muon or A mmc sm wohn aan, n., roi-1 washington, N. Y., u-

to Super-Herbe Syntens, Inc., New

liner York, N. Y., annotation o! Delaware man 'm 1:, 1n, sum No. 435,150

With the increasing trend toward metal and skeleton strucinres inaerofoils the chief concern of workers in this iield has been. thesolution of intricate problems involving the strength of materials,beams, joints, etc., and their resistance to tension and with little orno'regard tocostor duction.

The chief concern .of the present inventim is* to eliminate such metalbodies and frameworks and the technical problems incident to theirconstruction, and to provide molded nbrous bodies, wings and otheraerooilswhichmaybeproduced economically in large and arecomparablewiihanysiructuremaweightstrength basis.

While the invention'is useful in n silzl-A ationsoirtsidetheiieldofaeronauiicslshalldefscribeitsparticulartoaerofoilswhere the prevalent stream-line consla'ucmspecialproblems. thebodiosonf'msdanydiredshapeorsize, unitingsuperimposedlayezsotiihrousmaterialswhosechamcteristcsaredetenninedinadvance, makineiteasytoagrvensmnauaofconstructiononeeithasbeenset. Whereitisdesirabletoconstructahodyintwommeseclsionslprovideaoiniorthesectillni,andalsoprovidespecialwhicharean- 'choredinthebody-orcmneciingthewingsor-wovenclothhewholebeing 1 otherpartsthereto.

The compositionofihernodedbodymayvary withdili'erentoriiensetowhichtheyareput. Inamm-cookforlighi small-powercratlemploy abaseofwovenstrawYmistanorthelzkeenrichiswrappedonthefan'mmoverlappingspii'albetweerrlayersof woodbrecementeuvelelby:tracingI'oicloselyto '-s m a cock-pit;

Figui is a side elevation showing the preferred method of Vconstructingan airplane fuselage of the mono-cock type;

Fig. 2 is a. similar view showing the construction of the tail portion;

Fig. 3 is a section on the line 3 3 of Fig. 2, showingthe method ofmolding the tail portion over a collapsible form;

Fig. 4 is a section on the line 4 4 of Fig. 1, showing a terminal platefor joining the two halves of the molded structure;

Fig. 5 is a section on the line 5-5 of Fig. v1, showing thereinforcement at the edge of the Fig. 6 is a perspective view of thecomposite structure with portions'broken away andlaid back to showdetails of construction;

Fig. 'I is a longitudinal section showing the several layers united asin Fig. 6 before being compressed in the mold;

Fig. 8 is a longitudinal section showing the joints between adjacentsections anchored in the molded material;

Fig. 9 is a fragmentary perspective view of the plate for securingthesections together; and

adapted for securing wings and other parts to the molded body.

Figs. 1 to 3 show my preferred method of constructing a mono-.cock intwo parts, and for this purpose I employ a separable form comprisingrigidsections 1 and 2 for the main body and a.v

collapsible section- 3 for the tail portion. By the section 3collapsible itis possible to mold the ared tail as an integral part ofthe rearhody portion without encountering diniculty in withdrawing itfrom the form when completed.

'The form assembled in thermanner described' is first covered withV alayerof paper which is ed on both sides, and a layer .of closely Fig. 10is a perspective view of a terminal cloth, and then wrap the compositeband tightly around the form with adjacent edges overlapping and theparanined side next to the form. In such case I make the paraiiinedpaper narrower than the cloth on one edge, as shown in Fig. 6, so thatthe edges of the cloth will overlap and lie cloth-e to-cloth and willthus be directly united by the layer of cement which is next applied.lDue to the fact that the paraiiined side of the cloth is next to theform, it is possible by ironing the cloth with a hot iron to cause itto'adhere even to concave portions such as the 'ilared tail end of theform, as well as to parts of thefo'rm where it is desirable .to breakthe continuity' of the bandage for any reason. The paraflined paperbeing next to the form alsoprevents the .molded body from sticking fastto the form.

A layer of plastic material 6 is next lspread evenly over the cloth 5.This material is'preferably wood cement consisting-of balsa wood pulpmixed with a light binder. On top ofthis cement I wrap a band ofinterwoven' straw. or rattan "l, cover it withanotherwlayer of'fwoodcement 8, and then applya nn'al-wrappingof woven cloth 9 having paramnedpaper 1101mpressed therein Yas previously described. .i f The straw orother mat f1 vispreferably composed of coarse tubular straws orreedswith the warps and wefts spaced so that their original tubularstructure is not destroyed .although tle reeds may be compressed attheir points of intersection, as shown in Figs. Gland 'I 'enabling'themat to withstand both tension and compression.

The mat of reeds thus constructedin the formv of a bandage is preferablywrapped on' the bias over the cement layer 6, as shown i'nFig. 1, withthe adjacent edges overlapping about 4an inch.

If desired, the mat may be wovenor cut on the bias and wrapped in simplecircles or 'in any other manner. After the clotch 9 and paramned paper10 are applied the body is covered by the matrix of the mold andcompressed into a compact integral structure with the cement fillingthespacesbetweenthereedsandthe clothlayers 5 and 9 pressed-firmly intothe cement. After removing the matrix of the mold the body is slippedoff the form and smoothed down and treated with any suitablefire-proofing materiaand other fin- `Bofar I have described the methodof molding the body without provision for the cock-pit or otheropenings, or the means for connecting the separate sections together. Inorder to provide for the cock-pit 12 shown in Fig. l, I form thisportion of the body the same as before exceptthatlterminatealllayersofmaterialat theline which is to denne the-edgeof the cock-pit, cut' tingoifthereedsandclothand spreadingthe cement upto the desired line. On top'of the upperlayerofcloth91layametal orotherrim13ofthedesiredshapehavingoutwardlyextendingiinslgnttingtherimtotheedgeof the cock-pit. This portion of thebody is then covered witha second layer of fibrous material which isappliedin the same way as before, an-

' choring the fins 14 between the two layers, and

blending smoothly into the main b0 upon the applicatim d pressure to thematrix of the mold. The 'joint between the two sections of the body 1smamma-m the manner showninrigs 1, 4,

8and9,andispreferablymade atapointwhere.thebodyiscireularincross-section. Thejointcomprisestwoterminalplateseachhavinganannularangeliandcloselyspacednsldhavingspikesl'lstruekuponoppositesidesthereof.

overlapping sheets of interwoven reeds sage of rivets or bolts 19 whichclamp the two sections 'ofthe body together.

Suitableterminal plates 20 may also be embedded vin the body forattaching the wings or other parts thereto. 'I'hese plates are providedwith spiked iins similar to those described above, and have eyelets 21or other suitable attaching means. Fig. 1 shows the method of attachinga wing 22 to the body by means of struts 23 which are fastened to spacedterminal plates 20; it being understood that the wings are alsoconstructed in the manner described above.

It will be evident that numerous changes may be made in the details ofconstruction herein shown and described without departing from theinvention as defined in the appended claims. v l

The invention claimed is: l

1. A composite molded body comprising partly overlappingA sheets ofcoarsely woven rigid fibrous 195 material completely encased in aplastic binder conned in a closely woven cover, all molded to shape andcompressed into an integral ,rigid structure.

2. A composite molded body comprisnghm substantially tubular warps andwefts'encased in a plastic binder and compressed into a rigid 3. Acomposite molded body comprising partly overlapping sheets of interwovenreeds having substantially tubular warps and wefts encased in a plasticbinder confined in a closely woven cover, all molded to shape andcompressed into an integral rigid structure.

4. A composite molded body comprising partly overlapping sheets ofinterwoven reeds having substantially tubular warps and wefts encasedinwoodflbrecementandcompreasedintoa rigid structure.

5. The method of molding laminated bodies on forms which comprisescovering the form with parailined paper, wrapping closely woven fabricover the paper, covering the fabric with a plastic ller, wrapping a bandof fibrous material 130 in spiral formation over said filler withadjacent edges overlapping, covering said fibrous material withadditional plastic filler, wrapping closely woven fabric over saidfiller, and compressing the whole into a compactv structure.

6.Themethodofmoldingaplasticbodyona formwhich compriseswrappingtheformwitha bandage including a layer of paraflined paperandawiderlayerofelothsothatadjacent edges of the cloth overlap and liecloth-to-cloth with 140 thepaperlyingnexttotheform, and spreading`plastic material over the cloth.

'1. A pliable bandage for use in molding plastic material on a form,.comprising a layer of parailined paper and. alayer of cloth enough 145widertbanthepapertopermitadjacentedgesof the cloth to overlap and liecloth-to-cloth when the bandage is wrapped over the form.

8. Apliablebandageforuseinmoldingplasticmaterialonafolm,cmnprisingalayerof50 paraiiined paper and a layer ofcloth which is wider on one edge than said paper so that adjacent edgesof the cloth will overlap and lie cloth-to-clothrwhen the bandage iswrapped over the form.

9. A pliable bandage for use in molding plastic material on a form,comprising a layer of paper paraiiined on both sides, and a layer ofcloth compressed onto one side of said paper, the cloth being wider onone edge than the paper so that adjacent edges of the cloth will overlapand lie cloth-to-cloth when the bandage is wrapped over the form.

10. A composite molded body comprising a relatively narrow mat composedof coarse tubular reeds wrapped in the shape of the iinished body withadjacent edges of the mat overlapping, and a binder covering both sides`of the mat and compressedinto the spaces between the reeds.

11. A compositev molded body comprising a band of interwoven tubularreeds spaced to maintain their original tubular structure andwrapped inthe shape of the'nished body, and a binder compressed into the spacesbetween the reeds iand uniting said reeds in a compact rigid strucure.

12. A composite molded body comprisng a band of interwoven tubular reedswrapped in the shape of the finished body with adjacent edges of theband overlapping, and a binder covering both sides oi' said band andcompressed into. the spaces between the reeds.

13. A composite molded bodyl comprising a band of interwoven tubularreeds wrapped in the shape of the nished body with a biased web and withadjacent edges of theband overlapping, and a binder covering both sidesof said band and compressed into the spaces between the reeds, the warpand weft reeds of said bend lbeing spaced to maintain their originaltubular structure.

14. A composite molded.' body comprising a. bandof interwoven tubularreeds wrapped in the shape of the iinished body with adjacent edges ofthe band overlapping, wood fibre cement covering both sides of said bandand compressed into the spaces between the reeds, and layers of' clothpressed rmly into the surface of the cement on opposite sidesof thereeds, the warp and weft reeds of said band being spaced to maintaintheiroriginal tubular structure.

15. A composite molded body comprising a band of interwoven tubularreeds wrapped in spiral formation in the shape of the nnished body with.adjacent edges of the band overlapping, wood nbre cementcovering bothsides of said band 'and compressed into the spaces between the reeds,and inner and outer fabric covers pressed rmly into the cement onopposite the warp and weft reeds of said band beingv spaced to maintaintheir original side's of said band,

tubular structure.

16. A composite vmolded body comprising a relatively narrow band ofinterwoven tubular reeds' wrapped in the shape of the nished body with abiased web and with adjacent edges of the band overlapping, wood brecement covering both sides of said band and compressed into the spacesbetween the reeds, and inner and outer tension and compression.

covers of closely woven cloth pressed rmly yinto the cement on oppositesides of said band, the warp and weft reeds of said band being spaced tomaintain their original tubular structure.

17. The method of molding laminated bodies on forms'which-comprisesspreading a plastic binder over the form, wrapping a band of interwoventubular reeds on the bias over the binder while still plastic, coveringthe band with a plastic binder, and compressing the whole into a compactrigid structure with the binder filling the spaces between theinterwoven reeds. 18. The methodof molding laminated bodies on formswhich comprises covering the form with l a plastic binder, wrapping aband of interwoven tubular reeds over said binder while still plastic,with the web on the bias and with adjacent edges of the bandoverlapping, covering the band with a plastic binder, and compressingthe `whole into a compact rigid structure with the binder lling thespaces between the interwoven reeds.

19. A molded shell-like aerofoil composed of fibrous vibration-dampeningmaterial comprising a mat composed of connected reeds and a fibrousbinder compressed between said reeds and uniting them into a compactrigid vstructure capable of withstanding tension and compression.

20. A molded shell-like aerofoil composed of brous vibration-dampeningmaterial comprising a mat composed of interwoven tubular reeds and abrous binder compressed into the spaces between said reeds and unitingsaid reeds into` a compact rigid structure capable of withstanding 21. Amolded shell-like aerofoil composed of iibrous vibration-dampeningmaterial comprising amat composed of interwoven tubular reeds spaced tomaintain their original tubular struc-k ture and a brous bindercompressed into the spaces between said reeds and uniting said reedsstanding tension and compression.

22. lA molded shell-like aerofoil composed of fibrousvibration-dampening material comprising a band `oi? interwoven tubularreeds wrapped in the shape of the aerofoil and a fibrous bindercompressed intothe spaces between said reeds and uniting said reeds intoa compact rigid structure .capable of withstanding tension andcompression.

23. A molded shell-like aerofoil composed lof fibrousvibration-dampening material comprising 11 'into a compact rigidstructure capable of with- 5 a band of interwoven tubular reeds wrappedin theshape of the aerofoil with adjacent edges of the band overlapped,and a fibrous binder compressed into the spaces between said reeds anduniting said reeds into a compact rigid'structure capable ofwithstanding tension and compression.

24. A molded shell-like aerofoil composed of fibrous vibration-dampeningmaterial comprising a bando! interwoven tubular reeds wrapped in theband overlapped-and a binder of wood-fibre cement compressed into thespaces'between saidthe shape of the aerofoil with adjacent' edges ofreeds and uniting said reedsinto a compact rigid 14o structure capableof withstanding tension and compression.

' WILLIAM HARPER, Jn.

